Wow. EGR port job.

You'll need some tools and parts for that. I'll vaguely tell you what you'll need and what to do. (Warning: I highly suggest that you bring it to a shop).

Tools you'll need:
1) electric cordless drill
2) drill bit (I forgot what size)
3) automotive dental pick with a 90 degree bend
4) vacuum cleaner or compressed air and an air gun
5) tap (with the same pitch as the pipe plugs. I forgot what size).
6) allen wrench (to install the pipe plugs)

Parts you'll need:
1) EGR valve gasket
2) 4 pipe plugs (I forgot what size)

On your intake manifold look for the fuel injectors. Directly underneath the injectors will look like a rail with round castings build onto the intake manifold. Once you've located it and understand where it is then you want to remove the EGR valve. Try cleaning this out first by poking it with the dental pick. Then you drill holes directly on top of the round castings. Once the holes are in place, you would want to vacuum out the aluminum pieces or you can blow them out thru the EGR passage. Then you use the pick again to poke inside the port. Vacuum or blow it out again. You then use the tap to make threads so you can install the pipe plugs. Clean the area out again then you can install the pipe using the allen wrench to cover or close up the holes.

You do not have to remove the intake manifold to perform an EGR port job. But as far as performance, you can Extrude hone the manifold or you can just polish it up using a 4" mini die grinder and a port and polishing kit. Be very careful if you decide to port and polish your own because the manifold is made of aluminum and it is very soft.

To port and polish you need these tools:
1) 4 inch long mini die grinder
2) port and polishing kit
3) torque wrench (when you reintalls the manifold)
4) grinder's grease
5) machinist blue (it is a spray paint, usually blue in color)
6) scribe or automotive dental pick

Parts that you need:
1) intake manifold gasket


First you spray the intake manifold mating surface with the machinist blue. Then use the intake manifold gasket using the bolt holes for alignment. Then you use the scribe or automotive dental pick to trace around the inside of the gasket. It should leave a mark on the intake manifold. (This is called porting. You pretty much want to make the ports on the intake manifold with the gasket). You then remove the gasket off the manifold and you can start polishing using the port and polishing kit. To prolong the sanding scrolls, you dip them in the grinder's grease. For best results you would want to also port and polish the cylinder head.